Process of producing double-sided holographic replicas

ABSTRACT

A double-sided, holographic replica comprises a web of transparent, thermoplastic, sheet material having a separate series of off-axis-recorded, phase-modulated holograms pressed into each of the opposite surfaces, respectively, of the web. Oppositely disposed (front and rear) holograms are such as to provide angularly displaced reconstructed images, respectively, when a monochromatic read-out beam is transmitted through the web. The double-sided holographic replica is made by first pressing the web and a first holographic master between a first pair of heated calender rollers to form one replica on one surface of the web, and then pressing the web, while thermoplastically adhered to the first master, and a second holographic master between a second pair of heated calender rollers to form another replica on the other surface of the web. The first and second masters are subsequently cooled and separated from the web.

United States Patent 1191 Hannan et al.

[4 1 May 6,1975

[ PROCESS OF PRODUCING DOUBLE-SIDED HOLOGRAPHIC REPLICAS [73] Assignee: RCA Corporation, New York, NY.

[22] Filed: Oct. 18, 1973 [21] Appl, No.: 407,545

Related U.S. Application Data [62] Division of Ser No. 296,861, Oct, 12, 1972, Pat. No.

[52] 1.1.8. Cl. 264/1; 264/284; 35013.5 [51] int. Cl. B29c 17/00; 829d 11/00 [58] Field of Search 264/219, 220, l, 284, 293; 350/35; 352/233 3,758,649 9/1973 Frattarola 4, 264/220 Primary Examiner-Robert F. White Assistant ExaminerJames B. Lowe Attorney, Agent, or FirmG. H. Bruestle; B. E. Morris [5 7] ABSTRACT A double-sided, holographic replica comprises a web of transparent, thermoplastic, sheet material having a separate series of off-axisrecorded, phase-modulated holograms pressed into each of the opposite surfaces, respectively, of the web, Oppositely disposed (front and rear) holograms are such as to provide angularly displaced reconstructed images, respectively, when a monochromatic read-out beam is transmitted through the web. The double-sided holographic replica is made by first pressing the web and a first holographic master between a first pair of heated calender rollers to form one replica on one surface of the web, and then pressing the web, while thermoplastically adhered to the first master, and a second holographic master between a second pair of heated calender rollers to form another replica on the other surface of the web. The first and second masters are subsequently cooled and separated from the web.

4 Claims, 7 Drawing Figures PATENTEUHAY' BISTS 3.882.207

sum 1 or 2 TRANSPARENCY REDUNDANCY MEANS 2- READ-OUT BEAM AXIS REAL IMAGE x PROCESS OF PRODUCING DOUBLE-SIDED HOLOGRAPHIC REPLICAS This is a division of application Ser. No. 296,86l, filed 12, Oct. I972, now US. Pat. No. 3,790,245.

BACKGROUND OF THE INVENTION This invention relates generally to holograms, and, more particularly, to holographic replicas formed in the opposite surfaces of transparent sheet material, and to a method of making the same.

A hologram is a recording in the form of an interfer ence fringe pattern of all the information in a wave front of light obtained from an object that is illuminated with spacially monochromatic light.

By the term phase-modulated holograms," as used herein and in the appended claims, is meant holograms made by the technique of phase holography, which comprises, for example, projecting interference patterns, produced by the phase delay of two light beams, onto a recording medium that is developed to provide relief patterns, in a manner well known in the art.

It has been proposed to prepare phase-modulated holograms on a photoresist coated on a web substrate. When the photoresist is exposed directly with a holographic image of an object, and the photoresist is developed, the resulting phase-modulated hologram is termed an original hologram. A metal holographic master can be prepared from the original phase-modulated hologram by electroless plating and/or electroplating techniques to reproduce the holographic information on the metal master, in a manner known in the art. The advantage of preparing a metal master is that many holographic replicas can be pressed from a single metal master because of its dimensional stability.

It has also been proposed to make holographic replicas by pressing holographic relief patterns from a holographic master onto one surface of thermoplastic sheet material. Because of the prior-art method of recording and playing back phase-modulated holograms, however, it has not been possible previously to make a practical holographic replica by pressing holographic information onto the opposite surfaces of the same thermoplastic sheet material. The reason for this is that prior-art methods of making phase-modulated holograms comprised exposing the recording medium with a light interference pattern wherein the plane defined by the object beam and the reference beams was disposed perpendicularly to the longitudinal axis of the recording medium. By the term longitudinal axis," as used herein is meant the imaginary axis of the hologram that is perpendicular to the plane defined by the object and reference beams in prior-art holograms, regardless of the actual position of this axis to the horizontal. If these prior-art relief patterns (replicas) of holograms were pressed onto the opposite surfaces of a transparent tape, for example, the reconstructed images of both the front and rear holograms would be superimposed on each other when the holographic replicas were played back, producing an undesirable result.

We have found that when the longitudinal axis of a holographic recording medium is disposed at an ob- Iique angle (other than 90 or zero degrees) to the plane formed by the object and reference beams, an off-axis, phase-modulated hologram can be made by a method of holographic recording, herein referred to as a tilted off-axis recording, described in US. Pat. No. 3,619,052, issued on Nov. 9, 1971, to W. .l. Hannan,

the coinventor herein. If holographic masters are made from tilted off-axis, phase-modulated hologram recording media, then a transparent sheet material can be pressed on opposite surfaces with such masters, and the resulting double-sided holographic replica can be played back with a transmitted, monochromatic, readout beam so that the projected, reconstructed image from the holographic replica on one surface of the sheet material is angularly displaced from, and does not interfere with, the projected reconstructed image from the holographic replica on the opposite surface of the sheet material.

SUMMARY OF THE INVENTION A novel information recording medium comprises a transparent sheet material with a separate relief pattern on each of the opposite surfaces of the sheet material.

In a preferred embodiment of the novel recording medium, a different tilted off-axis holographic relief pattern is formed on each of the opposite surfaces of a web of transparent sheet material. Oppositely disposed (front and back) relief patterns are such as to provide angularly displaced reconstructed images, respectively, when a monochromatic read-out beam is transmitted through the sheet material.

In another embodiment of the novel recording medium, the relief pattern on at least one of the opposite surfaces of the sheet material is a tilted off-axis hologram.

The novel method of making double-sided relief pattern replicas comprises pressing a relief pattern, as from a first master of a tilted off-axis recording hologram, onto one surface of a thermoplastic sheet material at a temperature below the flow temperature of the thermoplastic material but sufficient to cause the sheet material to adhere temporarily to the first master, and then pressing a relief pattern, as from another master, onto the other side of the thermoplastic sheet material while the sheet material is still adhered to the first master. The thermoplastic sheet material is next cooled and the masters are separated therefrom.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary, perspective view of a novel, double-sided, holographic replica, showing a separate series of replicated holograms on opposite surfaces, respectively, of a flexible, transparent web of thermoplastic sheet material;

FIG. 2 is a schematic drawing of an arrangement of apparatus for recording a tilted off-axis hologram, corresponding to spacial information on a transparency, onto a hologram recording medium;

FIG. 2a is a cross section of the diagram shown in FIG. 2, taken along the line 2a-2a and viewed in the direction of the arrows;

FIG. 3 is a schematic diagram of an arrangement of apparatus for playing back a tilted off-axis recorded hologram to reconstruct an image of spacial information on a photosensitive imaging surface of a television camera;

FIG. 4 is a schematic diagram of apparatus used in the method of making double-sided holographic replicas on a web of transparent, thermoplastic sheet mate rial;

FIG. 5 is a cross section of a portion of the apparatus shown in FIG. 4, taken along the line 5-5 and viewed in the direction of the arrows; and

FIG. 6 is a cross section of a portion of the apparatus shown in FIG. 4, taken along the line 66 and viewed in the direction of the arrows.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIG. 1 of the drawing, there is shown a fragmentary perspective view of one embodi ment of a novel information recording medium in the form of a double-sided holographic replica 10. The holographic replica 10 comprises a web 12 of transparent sheet material with one series of phase-modulated holograms 14 pressed into one surface 16 of the web 12 and another series of phase-modulated holograms 18 pressed into an opposite surface 20 of the web 12.

The holograms 14 and 18 are relief patterns that are impressed in the surfaces 12 and 20 of the web 12, respectively, by metal masters in a novel method hereinafter to be explained. Each of the holograms 14 and 18 may be considered to have a longitudinal axis 21 extending in the intended direction of travel of the web 12. The web 12 is preferably of thermoplastic polymeric sheet material to provide a stable, flexible, transparent, and isotropic medium for the holograms l4 and 18 pressed thereinv The web 12 is also of an optical quality and transparency at least equal to that of window glass.

A web of flexible, transparent, cast-vinyl, thermo plastic material, having a thickness of between 1 and 6 mils, has been found satisfactory for the web 12. Cast vinyl has been found superior to calendered vinyl in that the former provided better optical clarity and less noise and stress patterns under polarized light than the latter. A typical web 12 for storing information to be played back through a television receiver is about onehalf inch wide with holographic information thereon in a series of relief patterns of about X mm? However, a web 12 of almost any width and length can be used provided that the holographic information can be pressed therein. A typical web 12 is about 2 mils thick, and the peak to valley depth ofthe surface corrugations that form the phase-modulated holograms 14 and 18 (holographic contours) is on the order of between 5 and 2,000A.

Inasmuch as the holographic replica 10 will generally be used in conjunction with a web transport system, the web 12 should have physical characteristics such that it is not deformed under the tension of the transport system. For example, the web 12 should have a tensile strength of about 5,000 psi and a maximum elongation before rupture (at 25C) of 5 percent. The flow temperature of the thermoplastic web 12, of the type described, is 155 1C. A transparent, thermoplastic, vinyl material that has been found satisfactory for the holographic replica 10 is plasticized, polyvinyl chloride-vinyl acetate copolymer made by the Cadco Film Division of Cadillac Plastic and Chemical Co, Inc.. Detroit, Mich, formulation No. Cl()2.

The holograms l4 and 18 are relief patterns impressed upon the web 12 by metal masters of tilted offaxis recorded holograms. Referring now to FIG. 2 of the drawing, there is shown an arrangement of apparatus for making a tilted off-axis recorded hologram. A holographic recording medium 12a, which can be in the form of a length of substrate tape or web coated with a suitable photoresist. The length of the web (recording medium 12a) lies in a plane perpendicular to the paper but extends in a direction that is oblique to the plane defined by the object and reference beam axes 22 and 32', that is, the longitudinal axis 21a of the recording medium 120 forms an angle other than or zero degrees with the plane 23 that contains the object and reference beams, as shown in FIG. 2av A laser 24 emits a beam 25 of optical energy of a first given wavelength A A partially reflecting mirror 26, called a beam splitter, divides the laser output beam 25 into two component beams 28 and 30. Beam 30, after reflection from a mirror 31, forms a reference beam, directed along the reference beam axis 32, that impinges upon the holographic recording medium 12a.

The light beam 28 is passed through redundancy means 34, which may be a diffuser, or preferably a phase grating of the type disclosed in US. Pat. No. 3,650,595. The optical energy emerging from the redundancy means 34 illuminates a transparency 36 having a spacial pattern of information thereon to be reproduced. If a Fresnel hologram is to be made, a convex lens 38 may be omitted and the optical energy emerging from the transparency 36 may be applied directly to the holographic recording medium 120. If. however, a Fraunhofer hologram is to be made, the lens 38 is disposed in front of the transparency 36 at a distance equal to the focal length of the lens 38 so that the transparency 36 lies in the focal plane of the lens 38. In the latter case, the output of optical energy from the lens 38 is applied as the information beam about the information beam axis 22 to the holographic recording medium 120. The developed holographic recording medium provides a tilted off-axis hologram record i2b (FIG. 3) which can have a resolution of about one micron.

Referring now to FIG. 3, there is shown an arrangement of apparatus to play back the developed tilted offaxis hologram record 12b. A laser 42 produces a readout beam of optical energy disposed about a read-out axis 44 at a second given wavelength )t which may be the same as, or different from, the recording wavelength The read-out beam impinges upon the hologram record 12b at an angle of incidence .r, with respect to the normal 46 to the surface of the hologram record 12b.

The essential difference between the play-back tech nique of the tilted off-axis recorded hologram 12b and the prior-art play-back technique, other than the fact that the tilted off-axis hologram record 12b was recorded by a different technique, is in the orientation of the hologram record 12b with respect to the read-out beam axis 44 and a real image beam axis 48. The image represented by the hologram 12b is projected along the real image beam axis 48 and focused onto, for example, a sensitized surface 50 in a TV camera 52, by means of a lens 54. The surface 50 is at the focal distance of the lens 54; and the real image beam axis 48 forms an oblique angle x with the normal 46 to the surface of the hologram record 1212. The plane defined by the readout beam and real image beam axes 44 and 48, respectively, is oblique to the longitudinal axis of the hologram 12b. With the arrangement of apparatus shown in FIG. 3, scratches on the surface of the hologram record 12b will not be superimposed upon the reconstructed real image projected onto the surface 50 of the camera 52, as discussed in greater detail in the aforementioned US. Pat. No. 3,619,052.

If the hologram record 12b in H0. 3 were a doublesided tilted off-axis recorded holographic replica, such as the replica described in conjunction with FIG. I, the holographic replica 10 could be played back by the play-back arrangement shown in FIG. 3 so that only one series of holograms, such as the holograms 14 on one surface, is imaged on the surface 50 of the camera 52. To image the other series of holograms, such as the holograms 18 on the other surface 20 of the holographic replica 10, onto the surface 50 of the camera 52 without interference from the holograms 18, the holographic replica 10 would merely have to be reversed.

Referring now to FIG. 4 of the drawing, there is shown apparatus for the method of making the doublesided holographic replica 10 on the web 12 of transparent thermoplastic sheet material. The web 12 is unrolled from a supply roll 56 and directed: over a flanged guide roller 58, between a first pair of calender rollers 60 and 62, between a second pair of calender rollers 64 and 66, under a flanged guide roller 68, and rolled up on a take-up roll 70. The rollers 62 and 64 are heated, by any suitable means (not shown) and coated with layers 72 and 74, respectively, of silicone rubber. The rollers 60 and 66 are also covered with layers 76 and 78, respectively, of silicone rubber.

A first metal master 80 ofa series of tilted off-axis recorded holograms, such as of the holograms 14 on the surface 16 of the web 12 illustrated in FIG. I, is formed in an endless loop (as by welding, for example,) and disposed around rollers 82, 83, 84, 85, and 86 for rotation thereabout in the direction of the arrow 88 by any suitable motive means. A portion of the master 80 is also disposed between the first pair of calender rollers 60 and 62 and the second pair of calender rollers 64 and 66.

A second metal master 90 of a second series of tilted off axis recorded holograms, such as of the holograms 18 on the surface 20 of the web 12, shown in FIG. 1, is also formed in an endless loop (as by welding, for example,) and disposed around rollers 91, 92, 93, 94, 9S, and 96, for rotation thereabout in the direction of the arrow 98 by any suitable motive means. The master 90 passes between only the second pair of calender rollers 64 and 66. A blower 100 for blowing cool air onto the metal master 90 is disposed between the calender roller 64 and the roller 95. Another blower 102 is disposed between the calender roller 66 and the roller 85 for blowing cool air onto the metal master 80.

The method of forming a separate series of replicas of different relief patterns in each of the opposite surfaces of the web 12 will now be described with the aid of the apparatus shown in FIG. 4. The web 12 is unrolled from the roll 56, guided over the flanged guide roller 58 and onto the silicone rubber surface of the calender roller 60. The lower surface 16 (HO. 5) of the web 12 is brought into contact with the metal master 80 between the first pair of calender rollers 60 and 62. The temperature of the heated roller 62 is preferably about 130C, that is, below the flow temperature of the thermoplastic web 12. The pressure between the first pair of calender rollers 60 and 62 can range between 10 and 200 psi. The web I2 is fed through the first pair of calender rollers 60 and 62 at a speed of about 4 inches per second. Under the aforementioned condi tions, the metal master 80 presses impressions of the series of holograms 14 onto the surface 16 of the web 12, and the web 12 is temporarily thermoplastically adhered to the metal master so that it cannot move with respect to it.

Next, the metal master 80, with the web 12 adhered to it, is moved over the silicone rubber surface of the roller 66 and the second metal master is brought into contact with the surface 20 of the web 12 between the second pair of pressurized calender rollers 64 and 66. The calender roller 64 is heated to a temperature of preferably l00C, and the pressure between the rollers 64 and 66 is in the range between 10 and 200 psi. Under these conditions, a second series of holograms I8 is impressed onto the surface 20 of the web 12. The metal masters 80 and 90 are now cooled by cool air from the blowers 102 and 100, respectively, to a temperature below 30C. At this temperature the web 12 no longer adheres to the metal masters 80 and 90 and is moved under the flanged guide roller 68 and wound up on the take-up roll 70.

The thermoplastic web 12 should never be heated to the flow temperature thereof. The heat applied by the calender rollers, however, may be in the range from about 0.3 to 0.85 times the flow temperature of the web 12.

We have found that an improved double-sided holo graphic replica 10 is formed when the series of holograms for the opposite surfaces of the web 12 are applied in a sequential manner, that is, with two pairs of calender rollers, as shown in FIG. 4, rather than with only one pair, because it is relatively difficult to guide the web 12 simultaneously between two metal masters without unwanted slippage. Thus, by first guiding the web 12 onto the silicone rubber surface of the calender roller 60 and impressing the holograms 14 onto the surface 16 of the web 12 by the master 80, the web 12 adheres to the master 80 so that both the web 12 and the master 80 can be guided between the second pair of calender rollers 64 and 66 without any possible move ment between the web 12 and the master 80. Under these conditions, the holograms 18 can be impressed on the surface 20 of the web 12 with accuracy and in the exact positions desired. The depth of the holo graphic impressions (relief patterns) may vary between 5 and 2,000A.

None of the aforementioned parameters is critical, and it is possible to vary them somewhat and still provide high-quality replicas. The temperature and pres sure parameters will vary with the thickness of the thermoplastic web used, a somewhat higher temperature being necessary when a thicker web is used. We have also found that it is preferable to heat the calender roller in contact with the master rather than to heat the roller in contact with the replica (substrate) web. This latter procedure results in better reproduced holographic replicas. Also, the use of yieldable silicone rubher on the calender rollers tends to reduce unwanted slippage and provides improved holographic replicas.

The use of cast vinyls for the web 12 proved superior to calendered or extruded materials.

The blowers and 102, which may be conduits having a plurality of openings through which compressed air can pass, as disposed parallel to the masters 80 and 90, respectively, along a substantial length thereof so as to cool the masters sufficiently and thereby minimize distortion or elongation of the web when separating the web from the masters. Although it is preferable to cool the masters 80 and 90 to at least 30C before separating them from the web 12, the temperature of the masters 80 and 90 should be below 50C before separation is attempted.

The web 12 should preferably have a maximum elongation prior to rupture of percent at room temperature. Webs having greater elongation prior to rupture tend to have the replicated relief patterns distorted to such a degree as to degrade the image during play back. Also, the web should be flexible and capable of being wound on reels. While the examples described herein relate to pure vinyl material, the thermoplastic material may be in the form of a laminated tape, such as vinyl material coated on a Mylar base, if extra strength is desired.

Although the masters 80 and 90 are preferably made of nickel, other suitable metals or plastics may be employed.

Alternatively, instead of replicating a separate tilted off-axis recorded holographic series of holograms on each of the opposite surfaces of the thermoplastic web 12, one of the surfaces can have a relief pattern of audio information pressed therein rather than the second series of holograms.

What is claimed is:

l. A method of forming an information storage replica in the form of a continuous sheet of transparent, thermoplastic material having information on both sides of said sheet, said information being in the form of a surface relief pattern comprising a tilted off-axis recorded transmission hologram formed by object and reference beams which define a plane oblique to the longitudinal axis of the hologram comprising the steps Of:

passing said sheet and a first master containing a first relief pattern between a first pair of calender rollers while heating said first master to a temperature so that said sheet is heated to a temperature below its flow temperature, but one which causes said sheet to adhere firmly to said first master, to impress said first pattern into one side of said sheet, passing said sheet adhered to said first master and a second master containing a second relief pattern between a second pair of calender rollers while heating said second master to a temperature below the flow temperature of said sheet to press said second pattern into said sheet on the opposite side from said first pattern,

cooling said first and second masters below a temperature at which said sheet adheres to said masters, and

separating said sheet from said first and second masters,

2. A method as described in claim 1, wherein:

said first and said second relief patterns are pressed onto said one and opposite surfaces, respectively, at a temperature and pressure to cause said relief patterns to have a depth of between 5 and 2,000A.

3. A method as described in claim 1, wherein:

said first master is heated to about l30C,

said second master is heated to about C, and

the pressure between said calender rollers in said first and second pairs thereof is between 10 and 200 psi.

4. A method of pressing a separate series of off-axis,

phase-modulated transmission holographic replicas in the form of relief patterns from first and second metal holographic masters onto opposite surfaces, respectively, of a flexible, transparent thermoplastic web of sheet material, said method comprising the steps of:

a. passing said web and said first master between a first pair of calender rollers while indirectly heating said web to a temperature from about 0.3 to 085 times the flow temperature of said web as it passes through said calender rollers by heating said first master in contact with said web and causing said web to adhere temporarily to said first master, thereby pressing said first pattern onto one surface of said web,

b. passing said web and said second master, while said first master is still adhered to said one surface of said web, between a second pair of calender rol lers while indirectly heating said web to a temperature in the range from about 0.3 to 0.85 times the flow temperature of said web as it passes between said second pair of calender rollers by heating said second master, thereby pressing said second pattern onto the opposite surface of said web,

c. cooling said web to about 30C, and

. separating said web from said first and said second masters. 

1. A METHOD OF FORMING AN INFORMATION STORAGE REPLICA IN THE FORM OF A CONTINUOUS SHEET OF TRANSPARENT, THERMOPLASTIC MATERIAL HAVING INFORMATION ON BOTH SIDES OF SAID SHEET, SAID INFORMATION BEING IN THE FORM OF A SURFACE RELIEF PATTERN COMPRISING A TILTED OFF-AXIS RECORDED TRANSMISSION HOLOGRAM FORMED BY OBJECT AND REFERENCE BEAMS WHICH DEFINE A PLANE OBLIQUE TO THE LONGITUDINAL AXIS OF THE HOLOGRAM COMPRISING THE STEPS OF: PASSING SAID SHEET AND A FIRST MASTER CONTAINING A FIRST RELIEF PATTERN BETWEEN A FIRST PAIR OF CALENDER ROLLERS WHILE HEATING SAID FIRST MASTER TO A TEMPERATURE SO THAT SAID SHEET IS HEATED TO A TEMPERATURE BELOW ITS FLOW TEMPERATURE, BUT ONE WHICH CAUSES SAID SHEET TO ADHERE FIRMLY TO SAID FIRST MASTER, TO IMPRESS SAID FIRST PATTERN INTO ONE SIDE OF SAID SHEET, PASSING SAID SHEET ADHERED TO SAID FIRST MASTER AND A SECOND MASTER CONTAINING A SECOND RELIEF PATTERN BETWEEN A SECOND PAIR OF CALENDER ROLLERS WHILE HEATING SAID SECOND MASTER TO A TEMPERATURE BELOW THE FLOW TEMPERATURE OF SAID SHEET TO PRESS SAID SECOND PATTERN INTO SAID SHEET ON THE OPPOSITE SIDE FROM SAID FIRST PATTERN, COOLING SAID FIRST AND SECOND MASTERS BELOW A TEMPERATURE AT WHICH SAID SHEET ADHERES TO SAID MASTERS, AND SEPARATING SAID SHEET FROM SAID FIRST AND SECOND MASTERS,
 2. A method as described in claim 1, wherein: said first and said second relief patterns are pressed onto said one and opposite surfaces, respectively, at a temperature and pressure to cause said relief patterns to have a depth of between 5 and 2,000A.
 3. A method as described in claim 1, wherein: said first master is heated to about 130*C, said second master is heated to about 100*C, and the pressure between said calender rollers in said first and second pairs thereof is between 10 and 200 psi.
 4. A method of pressing a separate series of off-axis, phase-modulated transmission holographic replicas in the form of relief patterns from first and second metal holographic masters onto opposite surfaces, respectively, of a flexible, transparent thermoplastic web of sheet material, said method comprising the steps of: a. passing said web and said first master between a first pair of calender rollers while indirectly heating said web to a temperature from about 0.3 to 0.85 times the flow temperature of said web as it passes through said calender rollers by heating said first master in contact with said web and causing said web to adhere temporarily to said first master, thereby pressing said first pattern onto one surface of said web, b. passing said web and said second master, while said first master is still adhered to said one surface of said web, between a second pair of calender rollers while indirectly heating said web to a temperature in the range from about 0.3 to 0.85 times the flow temperature of said web as it passes between said second pair of calender rollers by heating said second master, thereby pressing said second pattern onto the opposite surface of said web, c. cooling said web to about 30*C, and d. separating said web from said first and said second masters. 